Panel veneer systems

ABSTRACT

The present invention relates to the field of mortarless, brick- and stone-like veneer systems for walls. More particularly, the present invention relates to suspension rails for providing mortarless or mortar-optional installations of brick- and stone-like panels for covering walls. Embodiments of the invention provide a cage-type suspension rail configured to be partially embedded in the panel and a universal hanging bracket that provides pullout resistance for the panels. An exemplary suspension rail comprises: a first four-sided frame with horizontally and vertically disposed sides; a plurality of posts disposed on and perpendicular to the first frame or the cross bars; a second four-sided frame in communication with the plurality of posts; an upper tab in communication with the first frame for connecting the rail to a surface; wherein the upper tab is disposed outside a perimeter of the first frame and a perimeter of a second frame.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation of parent application U.S.patent application Ser. No. 15/049,626 filed Feb. 22, 2016, which parentapplication published as U.S. Patent Application Publication No.20160168862 on Jun. 16, 2016. The parent application claims priority toand is a Divisional application of U.S. patent application Ser. No.14/665,224 filed Mar. 23, 2015, which '224 application published as U.S.Patent Application Publication No. 20150191911 on Jul. 9, 2015 andissued as U.S. Pat. No. 9,267,295 on Feb. 23, 2016. The '224 applicationis a Continuation-in-Part (CIP) of U.S. patent application Ser. No.13/918,017 filed Jun. 14, 2013, which '017 application published as U.S.Patent Application Publication No. 20130305646 on Nov. 21, 2013 andissued as U.S. Pat. No. 8,997,423 on Apr. 7, 2015. The '017 applicationis a Continuation-in-Part (CIP) of U.S. patent application Ser. No.13/179,831 filed Jul. 11, 2011, which '831 application published as U.S.Patent Application Publication No. 20120174516 on Jul. 12, 2012 andissued as U.S. Pat. No. 8,806,826 on Aug. 19, 2014. The '831 applicationclaims priority to and the benefit of the filing date of U.S.Provisional Application Nos. 61/362,740 filed Jul. 9, 2010 and61/486,850 filed May 17, 2011. All of these applications areincorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to the field of brick or stone-like veneersystems for walls. More particularly, the present invention relates tosuspension rails for use in mortarless or mortar-optional brick orstone-like veneer systems. The suspension rails include a cage-typesuspension rail and a universal bracket that resists pull-out of thebrick or stone-like veneers.

Description of Related Art

Conventional mortar-based facade systems, including brick and stone areas difficult to remove as they are to install. Although the strength ofa mortar-based system is generally an advantageous feature, such systemsare susceptible to a number of disadvantages. For example, installationof brick and stone using mortar requires favorable weather andtemperature conditions to be sure the mortar sets properly. This limitsinstallation, especially in areas where seasonal changes occur, torelatively dry and ambient conditions.

In contrast, modular mortarless systems can be installed year roundregardless of external weather conditions. Likewise, modular systemshave the advantage of ease of installation, not requiring special skillsand so can be installed by a range of installers, from thedo-it-yourself to the trained stone mason. Even further, mortarlesssystems because they do not have to be adhered to the entire surfacearea of a wall can provide better ventilation and moisture removal thanconventional mortar-based veneers.

Existing mortarless systems, such as those disclosed in U.S. Pat. No.8,322,103 entitled “Faux Brick with Suspension System,” use one or moresuspension rails to retain a panel resembling an arrangement of one ormore bricks. To affix the panels to a wall, the top and bottom edges ofthe panels are retained in a track of a separate, non-embeddedsuspension rail. Such a system is vulnerable to pull out from the wallduring extreme weather conditions (such as high winds) due to the railand the panel being separate pieces.

Another existing mortarless system is disclosed in U.S. Pat. No.7,841,147 entitled “Mortarless Facade System.” A system described inthis patent uses a suspension rail with a two semicircular loops, whichduring fabrication are embedded into the panels. The panels are thensecured to a wall using a fastening device or adhesive to secure thesuspension rail and thus the panel to the wall. In an embodiment, thepanel has a convex rounded upper edge and a corresponding concaverounded lower edge for mating with upper and lower panels of the system.The system provides two suspension rails for each panel, with only aportion of each rail embedded in the panel, along only two sides of thepanel. Such a design is susceptible to failure due to only a smallportion of the panel being supported by the suspension rail. An exampleof securing a wall panel with clips is disclosed in U.S. Pat. No.7,926,237. Both of these patents are hereby incorporated by referenceherein in their entireties.

Additionally, existing mortarless systems, do not have the advantage ofstrength to resist pullout of the modular panels. Modular mortarlesssystems are usually configured for convenience of manufacture at theexpense of strength and aesthetic appeal. For example, there is usuallyminimal overlap, if any, between the panels of existing modular systems.With no overlap between the tiles, it is relatively easy to insert atool between the panels and pry them away from the wall on which theyare installed. Likewise, with readily apparent joints or seams betweenpanels, it is usually instantly recognized that the system is a facade.Compounding the issue is that for ease of manufacture the panels areusually configured as a single universal shape panel. When panels of thesame size and shape are installed together in a system it is typicallyquite easy upon visual inspection to identify the outline of each panel.

What is desired is a facade that has the appearance and strength of astone and mortar or brick and mortar installation, but which is costeffective to manufacture and install. Ease of installation is also aplus without compromising on aesthetic appeal. Thus, what is needed is amodular, preferably non-mortar system that addresses the disadvantagesof conventional mortar-based systems, but has the strength, ease ofinstallation, and aesthetic appeal of and aesthetic similarity to theseconventional systems.

SUMMARY OF THE INVENTION

To address these issues, embodiments of the present invention providesuspension rails whether embedded or stand alone, for use in mortarlessor mortar-optional veneer systems comprising a plurality of panels. Alsoincluded within the scope of the invention are the panels themselves,the as well as methods of making the panels and methods of using thesystems of the invention.

Embodiments of the invention provide a cage-type suspension railconfigured to be partially embedded in the panel comprising: a firstfour-sided frame with horizontally and vertically disposed sides; aplurality of posts disposed on and perpendicular to the first frame orthe cross bars; a second four-sided frame in communication with theplurality of posts; an upper tab in communication with the first framefor connecting the rail to a surface; wherein the upper tab is disposedoutside a perimeter of the first frame and a perimeter of a secondframe. In embodiments, the perimeter of the first frame is larger thanthe perimeter of the second frame. In embodiments, the upper tab is indirect communication with the first frame but not the second frame.Embodiments may further comprise one or more side tabs disposedperpendicular to a vertical side of the first frame and parallel to theplurality of posts or one or more cross bars joining two or more sidesof the first frame.

Preferred are such facade panels, wherein the tab comprises one or morevoid. The void is preferably configured to receive a fastener to fix thesuspension rail and thus the stone-like or brick-like panel to a wall.Any number of voids can be used.

In embodiments, the tab for fixing the suspension rail to a surface canbe disposed completely or partially along a side of the first frame.Preferred is such a facade panel, wherein the tab is disposed completelyalong a side of the first frame and is in a stepped configuration withrespect to that side of the first frame.

A plurality of voids may also be disposed along a side of the firstframe opposing the side of the first frame with the tab. Having voids onboth the upper and lower edges of the suspension rail will allow foreasy alignment of the panels on a wall by aligning the voids on the tabof one suspension rail with the voids along the lower edge of anothersuspension rail.

In preferred embodiments, the facade panel includes a tab with a spacingand/or directional indicator. When installing the panels on a wall, thisindicator can be used to align panels in a second row disposed at adesired position relative to panels in a first row.

In embodiments, one or more cross bar of the suspension rail is disposedat an angle less than perpendicular to any of the four sides of thefirst frame. The one or more cross bat may be disposed in an Xconfiguration. The one or more cross bar may be disposed perpendicularto any of the four sides of the first frame and may be fortified with aperpendicular support. The four sides of the first frame may have awidth greater than their thickness and the four sides of the secondframe may have a thickness greater than their width.

Side tabs can also be incorporated into the suspension rail embodiments.Such side tabs are useful for ensuring proper spacing between panels ineach row. For example, the panel can comprise side tabs disposedperpendicular to opposing sides of the first frame and on sidesperpendicular to the side with the tab. This ensures that duringinstallation one panel is spaced a desired amount away from anotherpanel in a row by abutting the side tab of one suspension rail against acorresponding tab of the suspension rail of another panel.

The sides of the first frame can have a width greater than theirthickness and the sides of the second frame can have a thickness greaterthan their width. With the first frame wider than it is thick, thisprovides for a substantially planar face, which is helpful for a secureconnection with a wall by being supportive over a large planar area ofthe wall. The suspension rail can also have a rippled surface on theface that is intended to abut the wall. Such a rippled surface mayprovide for additional support and/or for ventilation between the walland rail.

In embodiments, the facade panel can have a perimeter of the first framethat is larger than a perimeter of the second frame. In this manner,when embedded in the panel, the second frame will be completely embeddedin the material and not be exposed. Preferred is a suspension rail wherethe second frame is entirely embedded in the molded panel and whereinthe posts are partially embedded in the molded panel to provide for agap between the first frame and the molded panel. Also preferred aresuch suspension rails that are 3-D printed.

Embodiments of the invention provide a cage-type suspension railconfigured to be partially embedded in the panel comprising: a firstsupport member with a planar face having a first support memberperimeter; a plurality of posts each with a first end disposed on andperpendicular to the first support member; a second support memberdisposed in communication with the plurality of posts at a second end ofeach post; a tab in communication with the first support member andhaving a planar face disposed in a stepped configuration relative to theplanar face of the first support member, such that an outline of thefaces of the first support member and the tab define a perimeter of thesuspension rail, which perimeter is larger than a perimeter of the firstsupport member.

Embodiments include a suspension rail wherein the first support memberand the second support members are configured as four-sided frames. Inembodiments, the perimeter of the suspension rail is larger than aperimeter of the second support member. In embodiments, the secondsupport member is disposed perpendicular to the posts and disposedparallel to the first support member. In embodiments, the suspensionrails may further comprise one or more side tabs disposed perpendicularto one or more sides of the first support member or one or more crossbars disposed in an X configuration.

In addition to cage-type suspension rails, embodiments of the inventionmay additionally include suspension rails that serve as universalbrackets for hanging a brick- or stone-like panel that resist pullout ofthe panels. The suspension rails can comprise an elongated planarmember, an upper and lower mounting bar, and means for receivingsecuring means for connecting the suspension rail to a substratesurface. Panels and facade system embodiments of the invention need notcomprise a suspension rail with a particular configuration nor compriseall of these functionalities, however, preferred embodiments include theinventive suspension rails as well.

Receiving means for the securing means that is incorporated into theuniversal bracket can be of any configuration. For example, thesuspension rail can comprise an elongated v-shaped groove disposedlengthwise below the upper mounting bar for receiving screws at anypoint along the width/length of the suspension rail. Holes, whethercircular or oblong, can alternatively be included to receive screws andcan be disposed at various points along the length of the suspensionrail.

Ideally, the suspension rail has some flexibility incorporated into itsstructure or is comprised of a material that allows for flexing orbending or one or both of the mounting bars. Such functionality caninclude structure in the form of a c-shaped groove along the length ofthe suspension rail to which the mounting bar is in communication with.The c-shaped channel allows for the mounting bar to be flexed toward oraway from the body of the suspension rail to allow for ease of insertionof the mounting bar into a facade system on installation.

Feet for embedding or attaching the suspension rail to the back side ofa facade panel can also be incorporated into the suspension rail. Thefeet can be disposed at any angle relative to the body of the suspensionrail, however, a perpendicular position is preferred. Additionally, itis preferred to connect the panel with the suspension rail in a mannerto provide an air gap between the facade panel and the elongated planarmember. The air gap will allow for any moisture that collects behind thepanels to drain away from the system and not interfere with theconnection between the panels and the wall surface after installation.

Embodiments of the invention include a suspension rail serving as auniversal bracket which comprises: an elongated planar member with upperand lower longitudinal edges, upper and lower c-shaped channels disposedalong and formed in part by the longitudinal edges of the planar member,one or more feet in communication with the planar member or the upper orlower c-shaped channel and disposed perpendicular thereto, a v-shapedgroove disposed lengthwise along and in communication with the upperc-shaped channel, an upper planar mounting bar disposed lengthwise alongand in communication with the v-shaped groove and parallel to the planarmember, and a lower planar mounting bar disposed lengthwise along and incommunication with the lower c-shaped channel and disposed at an anglein the range of about 135 to 180 degrees relative to the planar member.In embodiments, the upper planar mounting bar is disposed in a planespaced a greater perpendicular distance from the elongated planar memberthan a longitudinal edge of the lower planar mounting bar. Inembodiments, during use a surface of the upper mounting bar of asuspension rail of one panel in a facade system is capable ofoverlapping with a surface of the lower mounting bar of a suspensionrail of another panel in the facade system.

Included in embodiments of the invention are panel veneer systemscomprising at least two universal brackets for providing support againstpullout of the panels. Each universal bracket (otherwise referred to asa suspension rail) can provide a surface for engaging another panel orfor engaging with a corresponding bracket of another panel. Preferably,each bracket comprises an engagement surface substantially along thelength of one side of the panel, or a major part of the length thereof,such as 50% or more. The brackets can also be configured to be a singlepiece providing one or more, typically two, additional engagementsurfaces. Preferably, the bracket(s) are embedded in the panels duringthe manufacturing process or prior to installation to provide easy toinstall panels. The brackets, together with the length of the engagementsurfaces provided by the panels themselves, can provide a total engaginglength of 50% or more of the perimeter of the panel and up to 150% ofthe perimeter, or any engagement length between. Preferably, panels ofthe system with integral bracket(s) engage 100% to 150% of perimeterlength.

Embodiments of the invention also include, among other things, facadesystems, panels for facade systems, and brackets for hanging panels in asystem. In certain embodiments, the panels preferably comprise one ormore surfaces for engaging or overlapping other panels in the system.

Facade panels of this invention encompass modular facade panelscomprising: (i) a front face for forming part of a first facade, whereinthe face is formed as a plurality of stacked stones and has a concaverectilinear polygonal outline configured for mating with adjacent panelswhen installed in a facade system; (ii) a back side with a suspensionrail in communication therewith; and (iii) left and right sides forforming part of another facade in a different plane.

Embodiments of the invention may also include suspension rails with anycombination of features described herein.

The suspension rails of the invention are useful for mortarless ormortar-optional mounting of panels, including brick or brick-like, stoneor stone-like, or other suitable veneer. As components of veneersystems, the suspension rails provide for strength and ease ofinstallation of panels that have an aesthetic appeal similar totraditional mortar-based brick or stone systems.

The features of novelty and various other advantages that characterizethe invention are pointed out with particularity in the claims forming apart hereof. However, for a better understanding of the invention, itsadvantages, and the objects obtained by its use, reference should bemade to the drawings that form a further part hereof, and to theaccompanying descriptive matter, in that there is illustrated anddescribed preferred embodiments of the invention. The features andadvantages of the present invention will be apparent to those skilled inthe art. While numerous changes may be made by those skilled in the art,such changes are within the spirit of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate certain aspects of some embodimentsof the present invention, and should not be used to limit or define theinvention. Together with the written description the drawings serve toexplain certain principles of the invention.

FIG. 1 is a schematic drawing showing a front perspective view of anembodiment of an exemplary facade system of the invention comprisingpanels of single stones each with an embedded L-shaped suspension railor clip, where the plurality of stones is arranged to cover a portion ofa wall.

FIGS. 2A-C are schematic drawings illustrating an exemplary L-shapedclip.

FIG. 3 is a schematic drawing showing a top side perspective view of anexemplary panel of systems of the invention comprising an embeddedL-shaped suspension rail and a rounded upper edge or “bull nose” edge.

FIG. 4 is a schematic drawing showing a rear perspective view of anexemplary cage-type suspension rail according to the invention.

FIG. 5 is a schematic drawing showing a side perspective view of thesuspension rail shown in FIG. 4.

FIG. 6 is a schematic drawing showing a front perspective view of thecage-type suspension rail shown in FIGS. 4-5.

FIG. 7 is a schematic drawing showing a front side perspective view ofthe suspension rail illustrated in FIGS. 4-6.

FIG. 8 is a schematic diagram showing a front perspective view of thesuspension rail shown in FIGS. 4-7 in combination with anothersuspension rail demonstrating the self-aligning capability of thesuspension rails.

FIG. 9 is a schematic diagram showing a side perspective view of a panelof the invention with an embedded suspension rail, with spacing betweenthe panel and rail.

FIG. 10 is a schematic diagram showing a perspective view of an array ofmolds for manufacturing a plurality of panels of the invention, where asuspension rail is disposed in a mold to illustrate how a suspensionrail is embedded in a panel.

FIG. 11 is a schematic diagram showing a close up of a mold shown inFIG. 10 with a cage-type suspension rail placed within the mold.

FIGS. 12A and 12B are schematic diagrams of an exemplary cage-typesuspension rail of the invention (12A) and the rails embedded in panelsinstalled on a wall (12B).

FIG. 13 is a schematic diagram showing a perspective view of a finishedfacade installed on a wall with brick or brick-like panels and optionalmortar between the panels.

FIG. 14 is a schematic diagram showing a perspective view of a finishedfacade installed on a wall with stone or stone-like panels and optionalmortar between the panels.

FIGS. 15A and 15B are schematic diagrams of other exemplary panelembodiments of the invention.

FIGS. 16A-B are schematic diagrams showing a back perspective view (FIG.16A) and a side perspective view (FIG. 16B) of a panel embodiment of theinvention.

FIGS. 17A-C are respectively a side elevation view, a top planar view,and a bottom perspective view of a universal hanging bracket embodimentof the invention.

FIG. 18 is a schematic drawing of a mortarless veneer system comprisingmultiple universal suspension rails according to an embodiment of theinvention.

FIG. 19 is a representative post veneer system according to theinvention, which provides for seamless corners around the post beingcovered by the panel veneer system.

FIGS. 20A-B are front and back perspective views, respectively, of arepresentative first panel embodiment of the system illustrated in FIG.19.

FIGS. 21A-B are front and back perspective views of a representativesecond panel embodiment of the system illustrated in FIG. 19

FIGS. 22A-B are front and back perspective views of a representativethird panel embodiment of the system illustrated in FIG. 19.

FIGS. 23A-B are front and back perspective views of a representativefourth panel embodiment of the system illustrated in FIG. 19.

FIG. 24 is a representative veneer system according to an embodiment ofthe invention, which provides for seamless corners.

FIGS. 25A-E are respectively top and bottom planar views, a sideelevation view, and top and bottom perspective views of an exemplarypanel of the invention.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION

Reference will now be made in detail to various exemplary embodiments ofthe invention. It is to be understood that the following discussion ofexemplary embodiments is not intended as a limitation on the invention.Rather, the following discussion is provided to give the reader a moredetailed understanding of certain aspects and features of the invention.

Veneer System with L-Shaped Clip

Facade panels, suspension rails for supporting facade panels, and facadesystems incorporating such facade panels and suspension rails areincluded within the scope of the invention. Provided is a veneer systemcomprising a plurality of facade panels each with one or more embeddedsuspension rails. As shown in FIG. 1, a facade system 130 of theinvention can comprise one or more panels 100. Each panel is configuredto represent a single stone or brick (or may represent multiple stackedstones or bricks) and each panel comprises one or more suspension rails,such as an L-shaped suspension rail or clip 120, preferably embedded inthe rear face 101 of the panel 100. When installed on a substratesurface 10, the rear face 101 of the panel 100 faces substrate surface10. Here, the substrate shown is a piece of plywood, but can be anymaterial such as drywall, cement, hardy board, fiber board, etc. FIG. 1shows that systems 130 can have a plurality of panels 100 and canpreferably be arranged to cover a wall or a portion of a wall 10.

L-Shaped Clip

FIGS. 2A-C are schematic drawings illustrating an exemplary L-shapedclip 220 (otherwise referred to as an L-clip) that can be used inembodiments of the invention. In the context of this specification, theterms clip and suspension rail may be used interchangeably to refer toan embedded support for a panel of the system. In embodiments, at leasta portion of the clip or suspension rail 220 is embedded in the rearface of the panel (the side of the panel that faces the wall wheninstalled as a facade system). The L-shaped clip or suspension rail 220is preferably made of plastic or a composite material and can be quicklyand easily fabricated using a traditional plastic manufacturingtechniques, including by injection molding, thermoforming, or even usinga silicon, composite, or polyurethane molding process, or a 3-D printingmachine. The L-clip 220 can be fabricated from composite or metalmaterials. The typical thickness of the L-clip is between 0.1 and 0.5inches. The L-clip provides a first planar attachment member 221 and asecond planar embedding member 222, where the two planar members 221,222 are disposed relative to one another at substantially a right angle.In this specification, the planar members 221, 222 may also be referredto as a planar surfaces. Each of these components may be molded, carvedor shaped individually and then attached together to form the L-clip, orthe L-clip can comprise a single, seamless piece of material which isshaped to reflect these distinct sections. If metal or plastic is usedas the L-clip, a single piece of material can be provided and thenfolded into the desired L-shaped configuration.

As shown in FIGS. 2A-C, the second planar embedding member 222 cancomprise one or more protrusions 223 along an edge. The second planarembedding member 222 is the portion of the clip 220 that is embeddedinto the panel. The protrusion 223 may be elongated and may be disposedon the first planar member completely or partially along the width ofthe clip and can have a cross section of any shape. The protrusion onthe first planar member should be shaped and sized to resist pull outfrom the panel when the first planar member is embedded therein. Inpreferred embodiments, the protrusion is elongated with a cross sectionof a curvilinear or rectilinear polygon disposed approximatelyperpendicular to the planar surface. The thickness of the protrusion isapproximately the same as that of the first planar member. Each side ofthe first planar member typically has a length between 0.5-3 inches andall sides are approximately equal to one another in length. It is notcritical how wide, thick, or long the first or second planar members areand these features may be designed accordingly for a particular type ofpanel. Generally, the greater the dimensions, the greater the supportprovided to the panel, so a larger panel may benefit more from a largerL-shaped clip.

The first planar attachment member 221 is used to attach the panel to awall when the clip is embedded in a panel. The first planar attachmentmember 221 comprises an upper edge 224. In preferred embodiments, theupper edge 224 is shaped. Here, the upper edge 224 is shaped by removingthe corners of the material. The first planar attachment member 221 ispreferably elongated substantially in the shape of a rectangle. Althougha square or other configuration can be used for the first planarattachment member 221, the rectangular shape is desired to provide forthe clip to be embedded at a lower height within the panel, whileallowing for the second planar member to extend beyond the upper edge ofthe panel (as shown in FIG. 1). In one embodiment, the first planarattachment member 221 can have a width of about 0.5-1 inch and a lengthof about 1-3 inches, while the second planar embedding member 222 canhave a width of about 0.5-1 inch and a length of about 0.5-1 inch. Thesedimensions can be scaled up or down to accommodate larger or smallerpanels as desired. Due to the first and second planar members beingdisposed perpendicular to one another, together the two planar members221, 222 form an L-shape clip 220.

FIG. 3 is a schematic drawing showing a top side perspective view of anexemplary panel of systems 330 of the invention comprising an embeddedL-shaped suspension rail and a rounded upper edge or “bull nose” edge302. As shown, the L-clip is preferably embedded into the back of apanel using second planar embedding member 222 in a manner to allow anair space between the panel and the clip. In embodiments, this meansthat the second planar member 222 is embedded only partially into theback face 301 of the panel. Once installed on a wall by attaching thefirst planar member 221 to the wall, this gap between the clip and thepanel will allow for air flow between the panel and the wall and forcondensation or water to pass through the gap instead of interferingwith the panel or panel system. In existing technologies, especiallytraditional mortar systems, where there is no gap between the facade andthe substrate, the presence of water may degrade the veneer system. Thebull nose shaping 302 on the top and bottom edges of the panel 300 allowfor interlocking of the panels of the systems when stacked and installedon a wall. In embodiments, the upper edge is a convex rounded shape andis shaped and sized to interlock or mate with a lower edge of a panelthat is of a corresponding convex rounded shape. The upper or loweredges can also be configured to have a square cross-sectional shape,where one edge provides a protrusion and the other edge provides arecess for mating with and accepting the protrusion. Any shape edge canbe used to mate with another edge in the system. In embodiments, only aportion of the edge or less than the entire length of the edge is shapedfor interlocking with another panel.

Cage-Type Suspension Rails

Embodiments of the invention further provide a cage-type suspension railor clip. In the context of this specification what is meant by acage-type clip is a suspension rail with structure that is almostcage-like in appearance. For example, the suspension rail can comprise asubstantially planar member with a plurality of posts projecting atsubstantially a right angle from the planar member, which poststerminate in and are joined together by a ring of material disposed in aplane substantially parallel to the first planar member. In preferredembodiments, the cage-type rail is preferably made of plastic and ispreferably 3-D printed, but can be made according to any conventionalplastic manufacturing technique.

Preferred embodiments comprise a suspension rail serving as a cage-typesuspension rail configured to be partially embedded in the panelcomprising: a first support member with a planar face having a firstsupport member perimeter; a plurality of posts each with a first enddisposed on and perpendicular to the first support member; a secondsupport member disposed in communication with the plurality of posts ata second end of each post; a tab in communication with the first supportmember and having a planar face disposed in a stepped configurationrelative to the planar face of the first support member, such that anoutline of the faces of the first support member and the tab define aperimeter of the suspension rail, which perimeter is larger than aperimeter of the first support member.

For example, FIG. 4 is a schematic drawing showing a rear perspectiveview of an exemplary cage-type suspension rail according to theinvention. In the context of this specification, the directional termsused to describe the suspension rails and panels, such as top, bottom,left, right, rear, front, vertical, or horizontal, are not intended tobe used in a limiting fashion. Rather, these terms are used to indicateone way the panels and suspension rails can be installed but anydirection for any purpose is included. The clip can be fabricated fromplastic, composite or metal materials. The typical thickness of thematerial is between 1 mm to 0.5 inches, such as from 2-5 mm, for example3-4 mm. One or more components of the clip may be molded, carved orshaped individually and then attached together to form the cage clip, orthe cage clip can comprise a single, seamless piece of material.

As shown in FIG. 4, provided is a cage type suspension rail 420comprising: a first four-sided frame 421 with horizontally andvertically disposed sides. This is also referred to as the first planarattachment member 421, which when embedded in a panel is used to attachthe panel to a wall, especially by way of upper attachment tab 425. Thesuspension rail also comprises one or more cross bar 426 joining two ormore sides of the first frame; a plurality of posts 422 extendingperpendicularly from the first frame or cross bars; a second four-sidedframe 423 in communication with the plurality of posts; and a tab 425 incommunication with the frame for connecting the suspension rail to asurface.

In embodiments and to save on material costs the first planar attachmentmember 421 of the suspension rail can comprise a substantially planarmember with voids. In this embodiment, the planar member 421 isessentially a frame comprising two horizontal edges 427 and two verticaledges 428 with interior supports 426 connecting two or more edges of theframe. As illustrated, there are two interior supports 426 shown in an“X” pattern between the horizontal edges 427 and another interiorsupport 426 joining the two horizontal sides of the planar memberperpendicularly. In FIG. 4, the face of the planar member shown is thesurface that abuts a wall when installed. This face can be rippled 429as illustrated.

FIG. 5 is a schematic drawing showing a side perspective view of thesuspension rail shown in FIG. 4. In this embodiment, suspension rail 520comprises an attachment tab 525 along the upper horizontal edge 527 ofthe first planar member. This attachment tab 525 is provided in astepped configuration 540 from the upper horizontal edge 527 of thefirst planar member. Preferably, the upper attachment tab 525 is steppedaway from the upper horizontal edge 527 of the first planar member anamount that is the same as or slightly larger than the thickness of thefirst planar member. This stepped surface 540 is useful in that wheninstalling a plurality of panels on a surface, one suspension rail 520of one panel can be placed behind the suspension rail of another panel.For example, during installation of a veneer system, the lowerhorizontal edge 527 of one suspension rail can be positioned behind thetab of another suspension rail. The length of the horizontal edge 527can be disposed in contact with the edge of the first planar memberwhere the step 540 is located. In this manner, the suspension rails andthus the panels are self aligned during installation.

FIG. 6 is a schematic drawing showing a front perspective view of thecage-type suspension rail shown in FIGS. 4-5. As illustrated, the firstplanar attachment member 621 (otherwise referred to as the firstfour-sided frame) of suspension rail 620 comprises a plurality of posts622 disposed perpendicular to the first four-sided frame 621. Here,there are ten support posts 622, however, any number is acceptable,especially from 2-20, such as from 5-15, or preferably 6-10. The supportposts 622 can also be any configuration from cylindrical posts to planarmembers. Here, the support posts are shown as planar members, withplanar support posts being stronger and more desired. The support posts622 are connected to a ring of material 623 disposed in a plane parallelto the first planar member 621. This ring of material 623 is alsoreferred to as the second four-sided frame 623. The second four-sidedframe 623 can be any shape or thickness, as here it is illustrated as arectangle. The support posts 622 and the second four-sided frame 623 arethe portions of the suspension rail that are embedded in a panel.Preferably, the support posts of the suspension rail are embeddedpartially in the panel to leave an air space between the first planarmember and the panel. This air space is desired during installation ofthe panels on a wall to provide for ventilation between the panel andthe wall.

FIGS. 7-8 are schematic drawings of other views of the suspension railillustrated in FIGS. 4-6. As shown in FIG. 7, along the upper portion ofthe suspension rail 720 there is an elongated step 740 and upper tab725. In preferred embodiments, upper tab 725 comprises one or more voids741 and a spacing/directional indicator 742. Any number of voids 741along the horizontal edges 727 or upper tab 725 of the first four-sidedframe can be used.

As demonstrated in FIG. 8, during installation of the panels 800, thevoids 841 can be aligned with one another and the directional indicator(arrow) 842 aligned with an edge of a vertical side 828 of thesuspension rail. The plurality of voids can be used for receiving afastening device, such as a screw or mortar, and the directionalindicator can be used for easy and accurate orientation of the clipduring installation. The fastening device can include for exampleadhesive, or a nail, screw, bolt, or staple, for securing an object to awall surface. The dimensions of the clip are dependent on the size ofthe panel and are preferably sized such that a portion of the horizontaledges extend beyond the panel face. In most cases this length would notexceed 24 inches, however, the clip is scalable up or down toaccommodate larger or smaller structures.

Further illustrated in FIGS. 7-8 are additional support features 743,843 projecting perpendicularly from the first planar member (the firstfour-sided frame). Here, the additional support structures 743, 843 aredisposed on the “X” supports 726, 826 to provide additional strength tothe suspension rail. These additional support features can be disposedanywhere on the first planar member. The suspension rail can alsocomprise one or more side tabs 744, 844 for easy alignment of thesuspension rails and panels during installation of the systems. Sidetabs 744, 844 are preferably perpendicular supports along one or bothvertical sides 728, 828 of the first four-sided frame of the suspensionrail. During installation, the side tab 744, 844 of one suspension railis abutted against the side tab 844, 744 of another suspension rail toensure alignment of the panels with respect to one another. Together orseparately, the voids 741, 841 along the horizontal edges of thesuspension rail, and the spacing/directional indicator 742, 842, as wellas the side tabs 744, 844 can contribute to the self-aligning capabilityof the suspension rails.

Panel with Embedded Cage-Type Suspension Rail

FIG. 9 is a schematic diagram showing a side perspective view of a panelof the invention 900 with an embedded cage-type suspension rail 920,with spacing 945 between the panel and rail. As shown, only a portion ofthe support posts 922 are embedded in the panel material, which providesfor spacing between the panel and the suspension rail and consequently aventilation area between the panel and wall to which the panel isinstalled. Further, as shown in FIG. 9, the rear face of the suspensionrail 920 in one embodiment comprises a rippled surface 929 for increasedstrength or stiffness in the suspension rail.

Any material can be used to manufacture the panels, including plastic,rubber, wood, stone, metal, glass, cement, ceramic, porcelain, orcomposite materials. A preferred stone-like material that is lightweight can be manufactured from a combination of cement, aggregate,pigments, and admixes. Preferred materials are easy to mold into adesired shape or size and are of a consistency to allow for ease ofembedding one or more suspensions rail into the material.

Molds for Preparing Panels with Embedded Suspension Rails

Included within the scope of the invention is a method of manufacturingconstruction panels with embedded suspension rails. As shown in FIGS.10-11, a polyurethane or silicone mold 1010, 1110 can be use to make anydesired shape and size panel. Preferably, the panels and thus thecorresponding molds 1010, 1110 are constructed to give an appearancesimilar to brick or stone. Typically, the exterior facing surfaces ofthe panel are shaped by the mold and the back of the panel is notmolded. However, in embodiments and as discussed in more detail below,it may be preferred to shape or mold at least part of the back surfaceof the panel. To construct an embedded panel of the invention, themolding material for the panel (e.g., concrete or a composite) can bedeposited into the well 1011, 1111 of the mold either manually orautomatically. All five interior surfaces of the mold well 1011, 1111are configured such that when the material to be molded is placed in thewell an imprint on the final molded product will result, which imprinthas the appearance of brick or stone. The suspension rails (for example,L-shaped or cage type) 1020, 1120 are inserted, manually orautomatically, into the material to be molded, while the concrete orcomposite material is still in a flowable state. This is performed in amanner to dispose the second planar embedding member or the secondfour-sided frame of the clip into the material for the panel. Asillustrated in FIGS. 10-11, the suspension rail is positioned in themold to position the cage portion of the suspension rail in the materialto be molded. Vibrational agitation can be applied to the mold trays toremove air bubbles and ensure that the maximum amount of panel formingmaterial is in direct contact with the mold well. Removal of the airbubbles is generally preferred because air bubbles can both compromisethe structural integrity of the panel, and lead to unwanted deformitiesin the surface pattern. The molding material is allowed to harden orcure. The drying process can be performed at room temperature in air orat an elevated temperature.

As shown in FIGS. 10-11, and in preferred embodiments, the mold 1010,1110 has a shelf 1012, 1112 for holding the suspension rail 1020, 1120.This shelf positions the suspension rail automatically in a desiredposition for embedding the suspension rail in the panel. For example,the material for the panel fills the mold to a certain desired levelbelow the shelf. When the suspension rail is inserted into the materialthat will harden to form the panel, the suspension rail is embedded at aset depth into the panel by virtue of resting on the shelf whichsupports the perimeter of the suspension rail during the embeddingprocess. In embodiments, the mold is filled with the molding material toa depth that allows for an air gap between the panel and the suspensionrail when embedded therein. Due to the configuration of the first planarmember of the suspension rail (here, the first four-sided frame), voidsbetween cross bar supports allow for a machine to pick up the suspensionrail and place it on the shelf of the mold automatically. For example, amachine can be configured to hold onto the suspension rail at the “X”support position 1026, 1126, then release the rail when placed on theshelf of the mold. In this manner, the panels can be fabricated quicklyand easily, as well as uniformly. Each mold is designed andappropriately sized to prevent the suspension rail from being insertedcompletely into the molding material. Typically, the first planar memberof the suspension rail is disposed between about 0.2 to 2 inches abovethe molding material that hardens to form the panel. In preferredembodiments, there is a spacing between the panel and the suspensionrail of about 1-20 mm, such as about 2-15 mm, or about 3-10 mm, or fromabout 4-8 mm, such as about 5 mm. In one embodiment, this spacing isabout 0.3 inches. When the concrete or composite material hassolidified, brick or stone facade structures with embedded cage clipsare removed from the mold wells and packaged for delivery or sale.

During use or installation at a site, the panels can be installed on anysubstrate. Preferably, the panels are used to form a veneer of a wallsurface, whether indoor or outdoor. In one embodiment of an installationmethod, starting on the bottom of the wall, the facade element (panel)is positioned at a desired location. A fastening device such as a screwor nail is then driven through one or more voids disposed along thebottom and side edges of the suspension rail, and into the substrate.The next panel is then positioned such that a side tab of its suspensionrail is positioned adjacent the side tab of the panel/suspension railalready installed. This step is repeated until a first row of panels iscovering the desired length of wall. Once a first row of panels has beensecured along the bottom edge of the wall, a second row of panels isinstalled in a horizontal row above the first row. Each panel in thesecond row is initially aligned by inserting the bottom edge of thesuspension rail behind the top tab of a suspension rail in the first rowuntil the stepped edge of one suspension rail contacts the bottom edgeof the other. After the initial alignment, the panel being added to thesecond row is further positioned by horizontally sliding the panel andaligning its bottom edge voids with the voids of the top tab of thepanels in the first row. Even further, for creating a traditional bricktype installation, the edge of the panel being installed can bepositioned such that one corner of the suspension rail is in line withthe positioning indicator (arrow) of a panel in the first row. Afastening device such as a screw or nail is then driven through thealigned voids. This step is repeated until a second row of panels iscovering the desired length of wall. This procedure of installing thepanels one row at a time may be repeated until the desired area of wallhas been covered.

FIGS. 12A and 12B are schematic diagrams of an exemplary suspension railof the invention (12A) and the rails embedded in panels installed on awall (12B). As shown in FIG. 12A, the clip 1220 can comprise a firstplanar member 1221 comprising more voids in its face than material.Here, there is a frame of material 1221 supported by a cross bar typesupport 1226 joining the upper, lower, and side edges of the frame. Onthe rear face of the suspension rail, there are perpendicular supportposts (not shown) which terminate in a second frame of material 1223disposed in a plane substantially parallel to the first frame 1221.Optionally, the suspension rail 1220 can comprise one or more voids forreceiving a fastener to attach the suspension rail to a wall 1241. Asshown in FIG. 12B, the veneer system 1230 can comprise a plurality ofpanels with embedded suspension rails 1220 attached to a wall 10. Whenembedded in a panel, the suspension rail 1220 is embedded to a desireddepth in the panel. Here, the suspension rail measures % inch betweenthe first and second four-sided frame members and the suspension rail isembedded in the panel up to about ½ inch. In preferred embodiments, thesuspension rail is embedded into the panel from about 20-90% of thedepth of the suspension rail, such as from 30-80%, or from 40-70%, orfrom 50-60%. This panel features corresponding rounded edges forproviding a bull nose type lock 1202 upon installation of the panels andfor providing a panel that is easily removed from the mold duringmanufacturing. With this type of interaction between panels in aninstalled system, there is no need for grout as the wall to which thepanels are secured will not be viewable.

Panel and Facade System Embodiments

FIGS. 13 and 14 are schematic diagrams showing a perspective view of afinished facade 1330 installed on a wall with brick or brick-like panels(FIG. 13) and a finished facade 1430 with stone or stone-like panels(FIG. 14) with optional mortar between the panels.

FIGS. 15A and 15B are schematic diagrams of other exemplary panelembodiments of the invention. More particularly, FIG. 15A provides aZ-shaped panel 1530 comprising multiple stacked stones. FIG. 15B is apanel 1530 of multiple stacked stones in an overall block typeconfiguration. An optional feature of panels of the invention and asillustrated in FIGS. 15A-B is that the edges of the panel can comprise astepped surface 1503 for overlapping with other panels when installed ona wall. The overlap or stepped configuration makes it possible to have amortarless system since the wall surface will be obstructed from view bythe overlapping of the panels. The suspension rails illustrated in thisspecification can be used with these types of panels as well, or anypanel providing a stone, stone-like, brick, brick-like, or multiplestone, multiple brick, multiple stone-like, or multiple brick-likepanel. Facade panels of this invention can be configured to resemble andfunction as the panels disclosed in US Published Patent Application No.2012-0174516 entitled, “Locking Panel Veneer System,” which encompassmodular facade panels comprising: (i) a front face for forming part of afirst facade, wherein the face is formed as a plurality of stackedstones and has a concave rectilinear polygonal outline configured formating with adjacent panels when installed in a facade system; (ii) aback side with a suspension rail in communication therewith; and (iii)left and right sides for forming part of another facade in a differentplane.

FIGS. 16A-B are schematic diagrams showing a back perspective view (FIG.16A) and a side perspective view (FIG. 16B) of a panel 1600 embodimentof the invention comprising a corner facade element (panel), twoembedded L-shaped clips 1620, and top and bottom panel edges 1602 forinterlocking with other panels in a system. This panel embodiment has aspecially shaped end 1604, which allows the panel to be installed on acorner surface without revealing that the panel is manufactured asopposed to natural stone. For example, one end of the panel is shapedaround all sides of the panel to have a natural stone look. This type ofpanel is especially useful for covering corner surfaces, such that wheninstalled the end can abut the end of another panel covering an opposingsurface at the corner. Since all sides of the ends of the panels aremolded to have the look of natural stone, there is no indication at thecorner that the panels are manufactured. Corners are usually vulnerableplaces where a system can be identified as manufactured or synthetic,but with the panels manufactured in this way, the system appears just asa natural stone or brick system would. One way of preparing this type ofembedded panel is by using a specially designed mold. For example, ashoe or slipper type mold can be used, which resembles a slipper.Instead of having a completely open upper surface (as shown in FIGS. 10and 11), a portion of the mold at one end is covered. This coveredportion of the mold has texturing on all sides of the mold to providefor a panel having one end textured or molded on all exterior surfacesto resemble brick or stone.

The molds, and consequently the panels, are scalable and can befabricated in a variety of sizes. Typically the panels have a heightbetween 1 and 24 inches, a length between 1 and 24 inches, and anaverage width between 0.5 and 4 inches. Preferably, the height and/orlength ranges from about 1-16 inches, or from about 2-12 inches, orabout 3-10 inches, or about 4-8 inches, such as about 5-6 inches, whilethe width ranges from ¾ inch to 2 inches. In embodiments, the panels canbe configured to comprise a single manufactured stone or brick or aplurality of stones and bricks.

Universal Hanging-Type Suspension Rails

In addition to cage-type suspension rails described above, embodimentsof the invention may include universal hanging-type suspension railsthat provide pull-out resistance. Included in embodiments of theinvention is a universal suspension rail or bracket comprising: anelongated planar member with upper and lower longitudinal edges, upperand lower c-shaped channels disposed along and formed in part by thelongitudinal edges of the planar member, one or more feet incommunication with the planar member or the upper or lower c-shapedchannel and disposed perpendicular thereto, a v-shaped groove disposedlengthwise along and in communication with the upper c-shaped channel,an upper planar mounting bar disposed lengthwise along and incommunication with the v-shaped groove and parallel to the planarmember, and a lower planar mounting bar disposed lengthwise along and incommunication with the lower c-shaped channel and disposed at an anglein the range of about 135 to 180 degrees relative to the planar member.In embodiments, the upper planar mounting bar is disposed in a planespaced a greater perpendicular distance from the elongated planar memberthan a longitudinal edge of the lower planar mounting bar.

FIGS. 17A-C provide various views of a hanging suspension railembodiment according to the invention. Provided by this embodiment is asuspension rail 1720 comprising: an elongated planar member 1721 withupper and lower longitudinal edges 1726; upper and lower c-shapedchannels 1725 and 1727 disposed along and formed in part by thelongitudinal edges 1726 of the planar member; one or more feet 1722 incommunication with the planar member 1721 or c shaped channel 1725 or1727 and disposed perpendicular thereto; a v-shaped groove 1723 disposedlengthwise along and in communication with the upper c-shaped channel1725; an upper planar mounting bar 1728 disposed lengthwise along and incommunication with the v-shaped groove 1723 and parallel to the planarmember 1721; and a lower planar mounting bar 1729 disposed lengthwisealong and in communication with the lower c-shaped channel 1727 anddisposed at an angle in the range of about 135 to 180 degrees relativeto the planar member 1721.

Embodiments of the invention include a dual extrusion suspension rail1720 (used interchangeably with bracket or hanger or rail) forincorporating (e.g, molding or forming) into each panel of the veneersystem. As shown in FIG. 17A, the suspension rail 1720 has a low profileplanar body with protrusions or feet 1722 extending from the body aboutperpendicular thereto. These protrusions or otherwise referred to asfeet 1722 facilitate embedding of the bracket into a material to bemolded into a desired shape (i.e., panel). Here, there are two feet 1722each of which comprises structure for preventing or resisting removal ofthe feet 1722 from the panel material once cast or molded. Theseprotrusions are integral to the body and in this embodiment made of thesame plastic material as the body. The protrusions extend lengthwisealong the body and can be molded into the panels of the invention toprovide a panel with hanger that will resist pull out from the panel andnot break free from the panel. Other means for securing the hanger tothe panel can be used, such as posts instead of lengthwise planarelements, however, the more material of the hanger that is molded intothe panel the more secure the hanger will be within the panel. Here, twofeet 1722 are provided, but any number can be used.

FIG. 17B shows the back face of the hanger, which comprises one or moregrooves in the plastic material along the length of the bracket toprovide flexibility in positioning of the engagement arms of thebracket. Any means for incorporating flexibility into the suspensionrail 1720 can be used, including using a plastic or metal material forthe suspension rail body that is flexible enough to bend into a desiredshape or has flexibility that allows for temporary bending of thesuspension rail 1720. Such flexibility is advantageous to allow for somevariability in the positioning of the panel into a facade system duringinstallation. As shown, another means for allowing some movement of themounting bars 1728 and 1729 relative to the planar member 1721 can beprovided by the c-shaped channels 1725 and 1727 that extend lengthwisealong the edges of the planar member 1721.

With respect to the two elongated engagement arms (mounting bars) 1728and 1729, these arms can be configured such that the bottom surface ofone arm is capable of overlapping with the top surface of the other armon a different bracket. When embedded in a manufactured stone, theuniversal brackets can be disposed in a manner to provide the elongatedengagement arms 1728 and 1729 along the horizontal length of the stoneat the top and bottom of the stone, or any part thereof. The engagementarms or mounting bars 1728 and 1729 need not be as long as the length ofthe panel to which they are connected, however, the greater the lengthof the suspension rail 1720, the greater the strength of the system.

The bottom arm 1729 of the bracket is capable of engaging or overlappingwith the top arm 1728 of another bracket of a panel disposed immediatelybelow the panel being placed into the system. The surfaces that engageone another are the surface of the bottom arm 1729 of a first panel thatfaces the panel and the surface of the top arm of another panel thatfaces away from the panel. Engagement in the context of thisspecification refers to overlapping surfaces and the surfaces need notphysically be in contact with one another upon installation, however, amore stable facade system will result if there is an interference fitbetween engagement arms 1728 and 1729 of the panels. Engagement arms1728 and 1729 are disposed in approximately the same orientation withrespect to the stone. In preferred embodiments, the upper engagement arm1728 is disposed in a plane parallel to the planar member or body 1721of the suspension rail 1720, while the lower mounting bar 1729 is angledslightly toward the planar member. For example, the lower mounting bar1729 can be fixed at an angle relative to the planar member 1721, suchas approximately in the range of 135-180 degrees away from the topsurface of the planar member. With the lower mounting bar 1729 at aslight angle relative to the planar member 1721 and thus relative to theupper mounting bar 1728, insertion of that panel into the facade systemis facilitated in that the lower engagement arm 1729 can be insertedbehind the upper engagement arm 1728 of another panel immediately belowthe panel being installed and engagement of the two surfaces will beautomatic due to the angle of the lower mounting arm 1729.

Engagement of the engaging arms of the bracket(s) is also shown in FIG.18. In some embodiments, the mounting bars in combination with the panelcan provide four surfaces for engagement to resist pull out of the panelor adjacent panels away from the wall to which they are attached.

FIG. 17C shows embedding feet 1722 disposed lengthwise along rail 1720.As is further shown, structure can be incorporated into the lengthwiseprotrusions (i.e., feet) 1722 to provide additional pull out resistance,such as opposing hooks or directionally opposed hooks as shown. Anotherfeature of the bracket is the V-shaped cut out 1723. This provides aposition for a screw or other securing means to be positioned whenfastening the panel to the wall. For example, once a panel is positionedinto a desired place within the veneer system, a screw can be used incombination with the V-shaped cut out to secure the stone panel to theface of the wall and provide the head of the screw in a recessedposition with respect to the bracket. The advantages of such a systemshould be immediately apparent in that the panels can be secured quicklyand easily to the wall and interlocked with one another to provide astrong veneer system without the need for mortar.

Other rail configurations are also included within the scope of theinvention. Preferred are universal brackets that can be installed alongany side of a panel without requiring a side-specific configuration. Auniversal bracket is smaller and requires less plastic material.Ideally, the universal bracket comprises two surfaces capable ofengaging corresponding surfaces of another bracket of the same type,although only one engagement surface of the bracket is actually used toengage a similar surface of another panel. In other words, two universalbrackets would be used for each panel as opposed to the single bracketdescribed in FIGS. 17A-C. The base of the bracket can comprise at leasttwo feet for facilitating the embedding of the bracket into a materialto be molded into a desired shape. Here, there are two feet each ofwhich comprises structure for preventing or resisting removal of thefeet from the panel material once cast or molded. Another feature of thebrackets is the two elongated engagement arms. The engagement arms areconfigured such that the bottom surface of one arm is capable ofoverlapping with the top surface of the other arm on a differentbracket. With two pieces needed to accomplish the same function as thesingle piece bracket described above, manufacturing of the stone panelsmay be slightly more complex due to the placement of two bracketsinstead of one. Non-universal brackets can also be used with the cost ofmanufacturing and complexity of the configurations being increased.

Specific universal brackets can include brackets measuring about 2inches by about 5½ inches for equipping a rectangular shaped extrudedpanel that measures about 11 inches long and 5½ inches wide. Again, itis not critical the size, shape, or material of any panel or bracket ofthe invention and dimensions and materials can be altered according todesired needs. The bracket(s) can be embedded in the panels duringmanufacturing in such a manner to dispose the brackets on the rear faceof the panel. Although any number of brackets can be used to support aparticular panel, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, and so on(limited only by the size of the panel and the size of the brackets),ideally two universal brackets are used (one at each of opposing sidesof the panel) and are disposed along the entire length of the panel.

For example, one bracket measuring about 5.5 inches long could bepositioned and embedded in one end of the panel that measures about 5.5inches long. A second bracket (universal, i.e., of the sameconfiguration as the first bracket) could be embedded at the opposingend of the panel that measures about 5.5 inches long. Such a panel wouldthen be inserted into the veneer system with the shorter 5.5 inch sidesdisposed horizontally to enable the brackets of the panel to engage withthe panels adjacent to it and disposed above and below the panel in thesystem.

Alternatively, one or two brackets could be disposed and embedded in thepanel along the 11 inch sides of the panel. In this case, one bracketcould be installed at each side (leaving about half the length of the11-inch sides unsupported with a bracket) or two brackets could bedisposed side by side along each 11-inch side so that the entire orsubstantially the entire length of each 11-inch side is supported bybrackets. A panel operably configured in this manner can be installedinto the veneer system so that the 11-inch sides were horizontal.

Using smaller universal brackets in this way further increases ease ofmanufacturing in that the brackets can be used both for smaller andlarger panels. More specifically, for example, two 5.5 inch bracketscould be used on opposing sides of a square panel measuring about 5.5inches on each side, or two or four 5.5 inch brackets could be used onan 11-inch side of a rectangular panel (as just described).

Yet another bracket embodiment can comprise engaging arms configured tobe about the same length and width and disposed in parallel, adjacent orabutting horizontal planes. It is not critical the degree to which theplanes in which the engaging arms lie are adjacent or if they abut oneanother, but it is important to note that the closer the clearancebetween the two, the tighter the fit between panels of the system andthe less movement of the panels will be experienced post-installation.

An alternative embodiment of a bracket according to the inventionincludes another single piece rail. Incorporated into its configurationare the engaging arms, only just one bracket is needed instead of two toprovide the corresponding top and bottom engaging arms disposed alongthe length of the panel at the top and bottom of the back portion of thepanel. In this embodiment the base or body of the bracket hangercomprises at least two feet for facilitating the embedding of thebracket into a material to be molded into a desired shape. Here, thereare four such feet each of which comprises structure for preventing orresisting removal of the feet from the panel material once cast ormolded. The structure for resisting removal of the feet from the moldedpanel in this embodiment comprises a hook at the end of each foot. Here,the hooks are oriented in the same direction, but can be oriented indifferent directions as well. Another feature of the brackets is the twoelongated engagement arms. The engagement arms are configured such thatthe bottom surface of one arm is capable of overlapping with the topsurface of the other arm on a different bracket. When embedded in amanufactured stone, the brackets are disposed along the horizontallength of the stone at the top and bottom of the stone. Both bracketsare disposed in the same orientation with respect to the stone. Asshown, the bottom arm of the bottom bracket is capable of engaging oroverlapping with the top arm of a top bracket of a panel disposedimmediately below the panel being placed into the system. The surfacesthat engage one another are the surface of the bottom arm of the bottombracket (of a first panel) that faces the panel and the surface of thetop arm of the top bracket (of another panel) that faces away from thepanel.

The universal suspension rails may be manufactured by any suitablemanufacturing method. In some embodiments, the universal brackets may bemade of hard plastic and 3-D printed or made from individual molds orother conventional plastic manufacturing techniques such as injectionmolding. In other embodiments, the universal brackets may be made ofsheet metal and manufactured by a CNC cutting machine according to CADdrawings, then pressed or bent to produce the individual features. Theuniversal brackets may be manufactured of unitary construction orindividual components joined together, such as through soldering orwelding.

Embodiments may include suspension rails that are modified versions ofthe suspension rails shown in FIGS. 4-8 and FIGS. 17A-C. The modifiedversions may omit one or more features, include one or more additionalfeatures, or substitute one or more features. Particularly, thecage-type suspension rails of FIGS. 4-8 may include features of theuniversal brackets of FIGS. 17A-C and vice versa. For example, oneembodiment includes a cage type suspension rail of FIGS. 4-8 thatincludes feet such as the feet 1722 shown in the universal suspensionrails of FIGS. 17A-C. For example, the feet 1722 may be in communicationwith the second four-side frame 623 as shown in FIG. 6. In otherembodiments, the feet 1722 may entirely replace the second four-sidedframe 623. The feet may be disposed at any angle to provide for anotherengagement surface with a panel. Another embodiment includes a universalsuspension rail of FIGS. 17A-C that includes at least one void 741, 841of the cage-type suspension rails shown in FIGS. 7 and 8. For example,one or more voids may be positioned along the mounting bars 1728 and1729 to provide for better alignment and means for securing the mountingbars together such as with a fastener. In addition, other embodimentswith combined features of the cage-type and universal suspension railsare possible. The present invention contemplates any combination of thefeatures of the suspension rails embodiments shown in FIGS. 4-8 withthose shown in FIGS. 17A-C and vice versa. Further, the suspension railsof FIGS. 4-8 and FIGS. 17A-C may include one or more features notdescribed herein alternatively or in addition to what is shown.Additionally, the type of panel that is mounted with the suspensionrail, whether brick or brick-like, stone or stone-like, or othersuitable veneer may also be interchangeable. Additional examples ofembodiments of the suspension rails of FIGS. 4-8 and FIGS. 17A-C andtheir advantages will be apparent to a skilled artisan, including thosenot specifically recited or depicted herein.

Veneer System Employing Universal Hanging-Type Suspension Rails

FIG. 18 is a schematic diagram showing installation of a veneer system1830 according to the invention that employs the inventive universalsuspension rails. This system, and any system or panel described in thisspecification, can be installed with or without mortar. One advantage ofthe systems of the invention is that mortar is not required, but can beoptional for additional support, strength, or longevity of the overallsystem. As shown in FIG. 18, each panel 1900 of this embodiment onceinstalled on a surface resists pullout of the panel and adjacent panelsby engaging or overlapping one or more adjacent panels along the panelitself or along their suspension rails, or a combination thereof. In theembodiment, the panels are installed on a wall surface by insertingscrews 1890 through v-shaped grooves 1823 in the hanging brackets.Preferably, as shown, each panel comprises engagement surfaces forengaging at least three sides of the panel with at least three adjacentpanels in the system. The overlapping surfaces can be any combination ofone or more surfaces of the panel itself or one or more surfaces of abracket installed in the panel. More particularly, each panel in thisembodiment has a vertical engagement surface 1811 that overlaps with thevertical engagement surface of an adjacent panel. Each panel also has ahorizontal engaging surface 1815, 1816 for overlapping with a horizontalsurface of another panel in the system. The hanging bracket(s) providetwo additional horizontal engagement surfaces 1828, 1829 for interactingwith horizontal surfaces of other panels in the system. In thisembodiment, the suspension rails are considered universal in that theycan be incorporated into either the upper part or lower part of the tileand provide the same function. Preferred embodiments have four engagingsurfaces on the panels themselves, such as on both vertical and bothhorizontal edges, and two additional engagement surfaces provided by thesuspension rails.

FIG. 19 shows a perspective view of a 4-panel system for covering thesides of a post that employs the inventive universal suspension rails.As shown, rows of four panels around the circumference of the post canbe arranged and stacked on top of previous rows until a desired amountof the post is covered. More specifically, four specifically shapedpanels can be installed along four corresponding faces of a post. Thefour panel pieces are configured to cooperate with one another tointerlock around the circumference of the post. Here, a cross section ofthe post is square, but any shape post can be used and appropriate sizedpanels selected for a particular design. The outline of the face of thepanel pieces is preferably shaped in the form of a concave rectilinearpolygon. In this manner the panels fit together like puzzle pieces sothat the outline of each panel is difficult to determine upon visualinspection of the installed facade. Further camouflaging the jointsbetween panels is the stacked stone appearance of the face of the panel.Due to the panel being divided up to look like a collection of severalsmaller stones, it is difficult to determine where the outline of thepanel starts and stops. No other existing modular facade system providesthis benefit.

As shown in FIG. 19 and FIGS. 20A-B, on the interior face 1912, 2012 ofeach panel 1900, 2000 (back side or side installed on post) there isprovided a hanger or bracket according to the invention. Any of theuniversal suspension rails 1920, 2020 described in this specificationcan be used. The hanger or rail is preferably a single piece anduniversal that can be incorporated into the panel during manufacture ofthe panel or attached to the panel prior to installation. Alternatively,no brackets can be used and the panels can be installed on a post orwall corner using mortar. As shown, the hanger extends an amount abovethe panel in which it is embedded to provide for interlocking of thepanels in the system by providing a surface for engaging with the hangerof another panel disposed on top. In this manner, each panel can besecured into the system by interlocking with a panel above and below.The bottom-most panel can be secured onto the post initially with asecuring rail that provides an engagement surface for that panel'shanger. Alternatively or in addition, as with any embodiment of theinvention, mortar, adhesive, or other securing means such as screws canbe used. In preferred embodiments, a v-shaped groove is provided inwhich screws can be inserted at any point along the length of thesuspension rail for hanging the bracket and panel to a surface. Thev-shaped groove can further comprise structure (such as a groove) forsupporting the head of screws and maintaining the screws in a certainposition within the v-shaped receiving groove.

As shown, the finished product is especially advantageous because themodular nature of the system is not readily apparent. It has been foundthat panels comprising three or more “stones” on the face and where someof the stones are in a staggered configuration to one another provide avisually pleasing veneer system in that the outline of each panel isdifficult if not impossible to detect by passersby.

Panels for providing a veneer to posts and columns according to theinvention need not be of any specific shape or size and such will dependgreatly on the particular application for which the panels are used. Forexample, when covering a post that is 4-inches square, the panels shouldbe greater than 4-inches wide, such that the entire face of each side ofthe post may be completely covered by a panel. Further, it is preferredthat each panel have finished “stone” that is visible from more than oneside of the post. Especially preferred are panels that are visible fromthree sides of the post.

As shown in FIGS. 19, 20A-B, 21A-B, 22A-B, and 23A-B, the four panelsconstituting one row around the post have a specific interlockingconfiguration. Though the panels may differ in shape, each panel hasthree faces, such that the panel can be seen on three sides of afinished post, or in three of the facades of the post. Moreparticularly, as shown in FIGS. 19 and 20, when installed as a veneer toa post, each panel has a first main face 1910, 2010 and two minor faces1911, 2011. The main face 1910, 2010 of the panel constitutes themajority of the surface area of one side of the post, while the twominor faces 1911, 2011 protrude into the surface area of a panel onadjacent sides of the post, such as the left and right sides 1911, 2011of the post. In this manner, the individual panels of the finished postveneer system cannot be detected upon mere visual inspection. Such apanel system 1930 differs from existing modular corner covering systemsin that each panel 1900, 2000, 2100, 2200, 2300 has an overall block orbrick shape as opposed to the typical L shaped configuration, whichallows for the panel to be seen on another side of the post or cornerjoint of two walls. L-shaped panels are difficult to manufacture and aresusceptible to breakage during shipping, installation, or other handlingof the panel pieces due to their awkward, non-stackable shape. Incontrast, panels of the invention can easily be stacked prior toshipping or installation. No other existing panel system comprisessubstantially planar panels with three faces that can be used forcovering a flat wall surface, a concave corner surface, and a convexcorner surface. Existing corner covering systems comprise a combinationof planar panels and a variety of L shaped panels to accomplish thisgoal. In contrast, the panels of the invention are universal in thatthey can be used to cover any surface.

Preferred embodiments include a panel facade system 1930 (see FIGS. 19and 20A-B) comprising: a plurality of facade panels 1900, 2000 eachhaving a front face 1910, 2010 for forming part of a first facade,wherein the face is formed as a plurality of stacked stones and has aconcave rectilinear polygonal outline configured for mating withadjacent panels when installed in the system; a back side 1912, 2012with a suspension rail 1920, 2020 in communication therewith; and leftand right sides 1911, 2011 for forming part of another facade in adifferent plane. Such panel facade systems can comprise a group panelsthe combination of which is shaped to tessellate a surface that wrapsaround a 270-degree corner or that wraps around a 90-degree corner orboth. What is meant by tessellate according to this specification isthat the panel shapes fit together like a puzzle, whether on a planarsurface or a combination of planar surfaces and corners, to form afacade with an annular-like rectangle or square configuration, meaningthe surface of the facade is disposed in four planes perpendicular toone another. The panel facade systems preferably comprise a number ofpanels in which at least three of the panels have different front faceoutlines chosen from z-shaped 2300, t-shaped 2100, and inverted t-shape2200 outlines (see FIGS. 21A, 22A, and 23A). The panels preferably incombination with each other are shaped to tessellate a surface thatwraps around a post. Likewise, the panel shapes can be grouped totessellate the interior surface of a room, such as around the base of aceiling as crown molding, if desired.

Provided in FIGS. 20A-B is a first panel 2000 of the panel veneer systemfor covering posts according to an embodiment of the invention.Respectively, are front and back schematic diagrams of the proximalpanel shown in FIG. 19. This proximal panel shows “stones” formed on theface of the panel in a staggered or offset configuration and stacked atleast 3-4 stones high and at least 2 stones wide. The outline of thepanel face is generally a z-shape polygon to provide three finishedfaces to the panel, a configuration that fits with other specificallyshaped pieces, namely the t shaped and inverted t-shaped panels, and tohide the overall outline of the panel when installed in the system. Thestones can be molded or carved into the panel and as such are notactually discrete stones but merely give the appearance of beingdiscrete stones. Panels 2000 can also comprise a collection of discretestones joined together by mortar or an adhesive, but such embodimentsmay have a reduced strength and are more complex from a manufacturingperspective and so are less preferred. Any number of “stones” orformations in the panel giving the appearance of individual dry stackedstones or individual stones joined together with mortar can be used. Ifthe panel constitutes one stone, then it will be easier for observers ofthe facade to detect the outline of the individual panels and toidentify the work as a modular system instead of the more desirableconventional brick and mortar look.

It has been found that panels 2000 comprising the formation of aplurality of stones with at least two stones disposed in an offsetmanner relative to one another are preferred. For example, the panelscan comprise only two stones, where the stones are stacked on top of oneanother in an offset manner. In such a configuration the panel is saidto comprise two stones high and one stone wide. Further preferred arepanels with at least three stones stacked high, wherein at least one ofthe stones is offset from another. What is meant by “offset” in thecontext of this specification is that where two stones abut, theabutting edge of at least one of the stones is not fully abutted by theabutting edge of the other stone. For example, an offset configurationcan simply be achieved by having one stone with a first length and asecond stone with a smaller length stacked immediately above or belowthe first, such that the longitudinal edges of the smaller stone do notline up with the longitudinal edges of the larger stone.

Another feature of embodiments of the invention is a modular facadepanel comprising a front face 1910, 2010 formed as a plurality ofstacked stones and a back side comprising a suspension rail, wherein anoutline of the front face is a concave rectilinear polygon. Panels withthis shape render the panel universal for any surface due to havingthree finished sides. As shown in FIGS. 20A-B, the left and right edges2011 of the facade panel 2000 are staggered or offset to allow for thestones of this panel to protrude into the face of the facade on the leftand right sides of the post or wall to which the panels are attached. Inthis manner, it is difficult to detect where the outline of each panelis thereby minimizing any negative aesthetic impact produced by thesystem upon installation. This configuration also allows for greatersecurity of the panels within the system, as there are additionalsurfaces for engaging surfaces of other panels of the system to preventmovement of the panels once installed. These panels are universal inthat they can be used to cover the planar surface of a wall whether ornot a corner is being covered. Additionally, the panels can be appliedto 90-degree corners (concave) or 270-degree corners (convex), withoutthe need for special corner-specific panel pieces in the facade system.

As shown, each panel 2000 in the system can also have a steppedconfiguration for providing additional engagement surfaces for securingthe panels in the system. FIG. 20B shows a recessed surface 2015 alongmost of the length of the bottom side 2014 of the back of the panel. Therecess 2015 of this panel 2000 can then be positioned in the systemabove a panel having a corresponding protrusion 2016 along its top edge2013, as shown in FIG. 20A. (A similar protrusion 1916 is also shown inFIG. 19.) As shown in FIG. 20A, this first panel also has a protrusion2016 on the top edge 2013 of the panel 2000, which can be interlockedwith a corresponding recess 2015 of another panel disposed above thispanel. The protrusions 2016 of the system can be the same height andlength for each panel 2000 and the recesses 2015 can be the same heightand depth for each panel 2000 so that any panel can be placed on top ofany other panel in the system. The recesses 2015 and protrusions 2016can be made to fit specific panels to ensure that a panel is not placedon top of an identical panel to ensure the individual panels remainundetected once installed in a system.

FIGS. 21A-B are schematic drawings of the front and back, respectively,of the right panel shown in the system of FIG. 19. This panel 2100comprises a suspension rail or hanger 2120 integral to or embedded inthe panel on its back side (side that faces or is installed on the postor wall) for interlocking with panels above and below the panel. Alsoincluded is a protrusion 2116 along the top edge and a recess 2115 alongthe bottom edge 2114 for engaging complementary surfaces of panels aboveand below this panel in the system. The face of the panel has astaggered configuration and its outline is basically T-shaped forextending into the face of the facades formed by the proximal panel andthe distal panel of the system shown in FIG. 19. This right panelcomprises at least 3-4 stones in height and at least 2 stones wide.

FIGS. 22A-B are front and back views, respectively, of the distal panelof the system shown in FIG. 19. This panel 2200 has the outline of aninverted T-shape and is configured for protruding into the face of theright and left panels installed in the system. This distal panelcomprises at least 2-3 stones high and at least 1-2 stones wide. Asshown in FIG. 22B, the panel 2200 can comprise stepped surfaces forsecuring multiple panels in the system, such as protrusion 2216 andrecess 2215.

FIGS. 23A-B are views of the left panel of the system of FIG. 19. Thisleft panel 2300 is at least 3-4 stones high and at least 2 stones wide.This panel is configured to be the same overall shape and have a facewith the same overall outline as the proximal panel. In this manner,only three distinct panels need to be used for each row of the system.The panels can be made of any configuration so that the panels of onerow interact with each other and subsequent or previous stacked rows inthe manner described, ie, interlocking with above and below panels atthe panel face by way of protrusion 2316 engaging with recess 2315 ofanother panel 2300 and/or hangers 2320 and/or protruding into the faceof adjacent panels.

Trim elements can be incorporated into the post systems of theinvention, such as trim to be disposed around the base of a post or totop off the post to provide a finished look. Additionally, a cap stonecan also be incorporated into the systems.

Embodiments of the invention provide a mortarless veneer systemcomprising: a plurality of panels for forming a facade on a substratesurface, wherein each panel comprises means disposed along two adjacentsides of the panel for resisting its removal from the facade and meansdisposed along two other adjacent sides of the panel for resistingremoval of adjacent panels from the facade, and wherein each panelcomprises at least one universal bracket, or a combination of two ormore universal brackets, embedded in or otherwise integral to the panel,wherein the bracket or brackets together provide structure disposedalong two opposing sides of the panel for resisting its removal from thefacade.

Additionally, embodiments provide a mortarless veneer system comprising:a plurality of panels capable of interlocking with one another to form afacade on a substrate surface, wherein each panel is operably configuredto comprise at least four planar surfaces for resisting its removal fromthe facade, and wherein each panel is operably configured to comprise atleast four additional planar surfaces for resisting removal of adjacentpanels from the facade.

Substrate covering systems are also included within the scope of theinvention, including facade and veneer systems for walls and ceilings orany other planar surface of interest. Preferred embodiments include awall covering system comprising: a plurality of panels for forming afacade on a wall, each having a front face with a perimeter of aselected length, wherein each panel has surfaces along its perimeter forengaging, in response to force, adjacent panels in the facade and thesurfaces have a combined length of at least 50% or more of the length ofthe perimeter.

Also included in specific embodiments of the invention is a wallcovering system comprising: a plurality of panels for forming a facadeon a wall, each having a front face and a perimeter around the frontface of a selected length, wherein each panel is operably configuredwith at least three planar surfaces for resisting its removal from thefacade in response to force by engaging with at least two adjacentpanels in the facade, and wherein the engaging surfaces have a combinedlength that is between 50% and 150% of the length of the perimeter.

Veneer systems comprising a plurality of panels each having a top facewith a selected perimeter length; wherein each panel has a steppedsurface configuration around its perimeter; such that, upon applicationof a pullout force applied to a panel: a) two of the stepped surfacesare capable of resisting removal of the panel by engaging with twoadjacent panels in the facade; and b) two of the stepped surfacesprovide pullout resistance for adjacent panels in the facade, arefurther embodiments.

Further embodiments include a veneer system comprising a plurality ofpanels each having a stepped top and bottom surface configuration and atleast one universal bracket embedded in or otherwise integral to thepanel, which, when installed as a facade and a central panel issurrounded on all sides by adjacent panels in the facade, all of theadjacent panels are capable of providing resistance to removal of thecentral panel due to the configuration of the stepped surfaces and theuniversal brackets. Even further embodiments include a wall veneersystem comprising a plurality of panels having a top face with aperimeter of a selected length and operably configured, such that wheninstalled on a wall, each panel adjacent to a central panel is capableof providing pullout resistance to the central panel along surfaces witha combined length that is about 90% or greater than the perimeter of thepanel face.

FIG. 24 shows a panel system 2430 of the invention as installed on thecorner of a wall surface. In this embodiment, the panels are installedon a wall surface by inserting screws 2490 through v-shaped grooves 2423in the suspension rails. In this embodiment the panels 2400 can beinstalled using suspension rails 2420 of the invention and/or mortar. Amortarless system is shown in FIG. 24, which provides a close-upperspective view of a facade system applied to two planar surfaces andan intervening convex corner. Similar to the post system, the wallsystem in this configuration comprises panels 2400 with the inventivehangers imbedded in the back side of the panel. Further security againstpull out is provided by a protrusion and corresponding recess on the topand bottom edges of the panel for interlocking the panel surfaces withpanel surfaces above and below each panel. The face of the panels isconfigured to have “stones” protruding into the face of an adjacentpanel on the corner so as to make it more difficult for determining theoutline of each panel and disguise the modularity of the system. Theshape of the panels is such that the panels are combined in a manner tofit together to completely cover the wall and corner surfaces withoutthe overall outline of each panel being detected.

Chair rail embodiments are encompassed by the invention as well. Someembodiments can include a suspension rail for attaching the chair railto a wall and within a facade system according to the invention. Moreparticularly, the chair rail can be used to top off a wall system at anypoint along the surface of the wall. A hanger can be incorporated intothe chair rail for installation. For example, the chair rail can bepositioned along the top of the wall panel veneer system and restthereon. Then the hanger can be secured to the wall with screws.

Modular fireplace stone surround systems are also included within thescope of this invention. The product components are provided in a systemin which the product can be fitted to any height and width fireplaceeasily, conveniently, and without requiring further finishing of thestone. For example, the top of the fireplace surround can be provided inthree or more component parts. A center diamond piece can be positionedon the wall in the desired location and attached thereto with thebracket incorporated therewith. Then the stones to be positioned alongthe length of the top of the fireplace can be cut to the desired lengthto fit the width of the fireplace. The cut ends of the stone are thenplaced adjacent the center diamond so that the unfinished ends arehidden by abutting up against a side face of the diamond. The finishedends of the stone (the uncut end) can then be positioned outwardly. Sidesurrounds to be placed vertically along the sides of the face of thefireplace can be provided as two components, a finished base and alength of material that can be cut to the appropriate size. In thismanner, the cut end of the stone can be placed in a position abuttingthe horizontal portion of the surround so that no unfinished ends areoutwardly facing.

Additional embodiments include a structural support system for securingthe panels to a wall, which includes holes in the horizontal supportmembers to allow for the drainage of any fluid that may seep in betweenthe veneer and the wall to which the veneer is attached. The bracketsembedded in the panels can be secured to the vertical supports of thisstructural support system to allow for additional ventilation and/ordrainage between the wall and the veneer.

FIGS. 25A-E are respectively top and bottom planar views, a sideelevation view, and top and bottom perspective views of anotherexemplary panel 2500 of the invention. These panels can be installed ina veneer system using conventional mortar, adhesive, or screws. Foradditional resistance against pullout, hanging bracket(s) fixed orincorporated into the back of the panel can alternatively oradditionally be used. As shown in FIG. 25A, the panel can be constructedof a light weight concrete product molded to form a locking stoneveneer. The “locking” feature of this stone embodiment is a steppedsurface 2516. What is meant by locking according to this specificationis that the structure is capable of overlapping with structure of anadjacent panel such that resistance is provided by the second panelagainst pullout of the first panel from the system. More particularly,the stone comprises a square face (but can be any shape) that is aplanar surface with four sides and with or without beveled edges. Asecond planar surface is stepped a selected distance below the face andappears along two sides of the stone. In essence, the panel appears tocomprise two identical shaped tiles stacked one on top of the other inan offset manner to provide two stepped surfaces 2516. When installed ina panel system according to the invention, such a stone would be capableof engaging two other stones abutting the two sides of this stone alongthe exposed stepped surface area. What is meant by engaging according tothis specification is that, when installed, the stepped surface 2516 orany engagement surface of the panel or its bracket will resist againstpullout of this stone or another stone from a veneer system according tothe invention. Once installed, the back side of the top horizontalstepped surface 2516 of this stone can be disposed in the panel systemin a manner that provides this stone overlapping and in contact with acorresponding surface of a stone placed above this stone. Likewise, theback side of the side vertical stepped surface of this stone can bedisposed in the panel system in a manner that provides this stoneoverlapping and in contact with a corresponding surface of a stoneplaced to the side of this stone. In this manner this stone will preventpullout of the stone(s) above it and the stone(s) to the side of it dueto the overlapping engagement surfaces.

The size of the stone panels is not critical. Preferred embodimentscomprise small panels having a face that measures about 4 inches byabout 8 inches, or a about a 0.22 sq. ft. face. A typical large sizestone could have a face that measures about 10¼ inches by about 12¾inches, or about a 0.91 sq. ft. face. Other stones could measure about 4inches by about 17½ inches or with a 0.49 sq. ft. face, or about 4inches by about 8¾ inches, or about a 0.24 sq. ft. face. Indeed, theseshapes and sizes are meant to be exemplary rather than limiting and anyshape or size panel can be used according to the invention. Similarly,any shape panel can also be used, including for example, square,rectangular, triangular, octagon, etc. shaped panels.

Further, any material can be used to manufacture the panels, includingplastic, rubber, wood, stone, metal, glass, cement, ceramic, porcelain,or composite materials. A preferred stone-like material that is lightweight can be manufactured from a combination of cement, aggregate,pigments, and admixes. Preferred materials are easy to mold into adesired shape or size and are of a consistency to allow for ease ofembedding the support brackets into the material.

FIG. 25B is a bottom plan view of the panel 2500 shown in FIG. 25A. Thebottom (or underside) of the stone also has a planar face and a planarstepped surface 2516 along the other two sides of the stone. The planarface of the stepped surface 2516 on the underside of the stone, onceinstalled, will act to prevent a stone placed vertically below thisstone and a stone placed horizontally to the left of this stone frombeing withdrawn from the system. In essence, the stepped planar surfaces2516 on the top and bottom faces of the stone are capable ofinterlocking with the stones abutting this stone on all four sides ofthe stone. More particularly, the two planar stepped surfaces 2516viewable from the top provide resistance against removal of the stonefrom the system, while the two stepped planar surfaces 2516 viewablefrom the bottom of the stone counteract removal of other stones adjacentto this stone in the system.

It is noted that for convenience only the orientations given in thisspecification, including top, bottom, above, below, right, left,vertical, and horizontal refer to viewing the system in its finalinstalled form, in which the system is viewed from the front. Thus, toeliminate any confusion, when viewing the system from the back side of apanel 2500 (as in FIG. 25B), the structure appearing on the right-handside of the drawing is in essence the structure that would appear on theleft-hand side of an installed system when viewing the face of such aninstalled system.

In preferred embodiments, the total length of all four stepped planarsurfaces 2516 totals more than 50% of the perimeter of the stone. Inthis embodiment, the top face of the stone is 4⅛ inches square with aperimeter of about 16½ inches. The bottom face of the stone is slightlysmaller at 4 1/16 inches square with a perimeter of about 16¼ inches.The two stepped surfaces 2516 of the top face are 4⅛ inches in lengthand the two stepped surfaces 2516 of the bottom face are 4 1/16 inchesin length. The total length of the stepped surfaces 2516 is about 16⅜inches. This corresponds with being about 99% of the length of theperimeter of the top face.

FIG. 25C shows a side elevation view of the panel 2500 of FIGS. 25A-B,FIG. 25D shows a top perspective view, and FIG. 25E is a bottomperspective view. As shown in these figures, the stone in thisconfiguration appears to have a top stone that provides the top face ofthe tile and a bottom stone that provides the bottom face of the tile,where the two stones are stacked slightly eccentrically. This embodimentis molded as a single piece, however, to obtain the two stepped surfaces2516, which are produced from the off center stacked-stone appearance.

The present invention has been described with reference to particularembodiments having various features. It will be apparent to thoseskilled in the art that various modifications and variations can be madein the practice of the present invention without departing from thescope or spirit of the invention. One skilled in the art will recognizethat these features may be used singularly or in any combination basedon the requirements and specifications of a given application or design.Other embodiments of the invention will be apparent to those skilled inthe art from consideration of the specification and practice of theinvention. In particular, embodiments may include suspension rails wherefeatures from one type of suspension rail are interchangeable orsubstitutable with features from another type of suspension rail andvice versa, include those embodiments not explicitly recited herein.Where a range of values is provided in this specification, each valuebetween the upper and lower limits of that range is also specificallydisclosed. The upper and lower limits of these smaller ranges mayindependently be included or excluded in the range as well. As used inthis specification, the singular forms “a,” “an,” and “the” includeplural referents unless the context clearly dictates otherwise. It isintended that the specification and examples be considered as exemplaryin nature and that variations that do not depart from the essence of theinvention are intended to be within the scope of the invention. Further,the references cited in this disclosure are incorporated by referenceherein in their entireties.

1-16. (canceled)
 17. A panel veneer system for covering a wall, thesystem comprising: a plurality of panels each having a top face with aselected panel perimeter length; wherein each panel has a plurality ofstepped surfaces around its perimeter, such that, when the plurality ofpanels is installed on a surface and upon application of a pullout forceapplied to one or more panels of the plurality of panels: (i) at leastone of the plurality of stepped surfaces of the first panel is disposedin a manner capable of resisting removal of the first panel from thesurface on which it is installed; and (ii) at least one of the pluralityof stepped surfaces of the first panel is disposed in a manner capableof providing pullout resistance to a second panel of the plurality ofpanels from the surface on which it is installed.
 18. The panel veneersystem of claim 17, wherein at least one of the panels of the pluralityof panels comprises an embedded bracket for hanging the panel on thesurface.
 19. The panel veneer system of claim 17, wherein the surface isa wall.
 20. The panel veneer system of claim 19, wherein at least one ofthe plurality of stepped surfaces of the first panel is disposed in amanner capable of resisting removal of the first panel from the wall byengagement with a stepped surface of an adjacent panel in the systemupon application of the pullout force applied to the first panel. 21.The panel veneer system of claim 17, wherein at least one of theplurality of stepped surfaces of the first panel is disposed in a mannercapable of providing pullout resistance to an adjacent panel in thesystem by engagement with a stepped surface of the adjacent panel uponapplication of the pullout force applied to the adjacent panel.
 22. Thepanel veneer system of claim 17, wherein one or more panels of theplurality of panels comprises at least four stepped surfaces.
 23. Thepanel veneer system of claim 17, wherein two of the four steppedsurfaces are capable of resisting removal of the first panel and two ofthe four stepped surfaces provide pullout resistance for one or morepanel adjacent to the first panel.
 24. The panel veneer system of claim17, wherein each panel of the plurality of panels has a rectilinearpolygonal outline.
 25. The panel veneer system of claim 24, wherein atleast one of the plurality of panels has a T-shaped outline.
 26. Thepanel veneer system of claim 24, wherein at least one of the pluralityof panels has an inverted T-shaped outline.
 27. The panel veneer systemof claim 24, wherein at least one of the plurality of panels has aZ-shaped outline.
 28. The panel veneer system of claim 24, wherein noneof the panels has an L-shaped outline.
 29. The panel veneer system ofclaim 24, wherein at least two of the plurality of panels have shapesthat are different from one another.
 30. The panel veneer system ofclaim 24, wherein each panel of the plurality of panels has a face whichis divided into a plurality of stacked stones.
 31. The panel veneersystem of claim 24, wherein each panel of the plurality of panels has aface which is divided into a plurality of bricks.
 32. The panel veneersystem of claim 17, wherein the stepped surfaces provide a combinedengaging surface length of between 50% and 150% of the panel perimeterlength.
 33. A panel veneer system for covering a four-sided structure,the system comprising: a first, second, third, and fourth panel; whereineach of the first, second, third, and fourth panels has a face capableof contacting one facade of a four-sided structure; wherein each of thefirst, second, third, and fourth panels is incapable of contacting morethan one facade of the four-sided structure; wherein, when the first,second, third, and fourth panels are assembled to cover the four-sidedstructure, at least one of the first, second, third, and fourth panelscontacts an adjacent panel on at least two different panel surfaces.